Drill cuttings with a drying agent

ABSTRACT

Described are stabilized materials and methods and systems for providing said stabilized materials. The system includes a first unit for mixing a first combination that includes a quantity of drill cuttings and a drying agent. The system may include a second unit for mixing the first combination with at least a binder and/or a surface acting agent and providing a second combination. The second combination is formed when the first combination is caused to have a reduced moisture content, transitioning from a first state to a second state. The reduced moisture content in the second state is at least 20% less than the moisture content of the drill cuttings. The first combination in a second state is a stabilized material. The first combination in a second state may be a dried material. The binder and/or a surface acting agent with or without additional additives are not introduced until the first combination is in the second state.

CROSS REFERENCE TO RELATED APPLICATIONS

Pursuant to 35 U.S.C. § 119(e), this application is a continuation ofU.S. patent application Ser. No. 14/719,150, entitled “Drill CuttingsWith a Drying Agent,” filed May 21, 2015, and naming Donald J. Kennedyand Jason R. Goodrum as inventors, which is a non-provisional of U.S.Provisional Application No. 62/001,258 entitled “Remediated DrillCuttings With a Drying Agent,” filed May 21, 2014, and naming Donald J.Kennedy and Jason R. Goodrum as inventors, the disclosures of which areincorporated herein by reference in their entirety.

BACKGROUND

The invention described includes materials stabilized and/or recycledand methods of making said materials.

Drill cuttings removed during drilling pose a potential biohazardbecause of pollutants or contaminants contained in the drill cuttings.Drill cuttings include about 50% fines with the remainder containingcoarse aggregate, moisture and any additive (e.g., drilling mud) used inthe process of drilling. One such additive is a fuel source containinghydrocarbons, such as diesel. The fuel source amount will vary and may,in some instances, account for about 5-15% or up to or more than 30% ofthe total, of what may be referred to as drill cuttings. Because of thefuel source as well as other potential contaminants in the drillcuttings, drill cuttings require stabilization, e.g., remediation and/orrecycling, to be re-used, which will necessitate improvements toexisting methods of containing the contaminants found in drill cuttingsin order for said material to be considered stabilized, remediatedand/or deemed as recycled and suitable for re-use.

OVERVIEW

Described herein are methods of preparing stabilized and/or recycledmaterials and the stabilized or recycled materials obtained from saidmethods. Said stabilized and/or recycled materials are suitable forre-use. Said stabilized or recycled material suitable for re-use are soobtained that contaminants are also contained in the materials so thatsaid materials when stabilized are suitable for re-use and/or may bedeemed suitable for recycling. Said stabilized and/or recycled materialssuitable for re-use are so obtained that contaminants are not releasedfrom the materials when stabilized or with re-use.

In one or more embodiments, a method described herein includes preparinga first combination of components. Components for the first combinationinclude drill cuttings and a drying agent. The first combination isprepared by comingling or blending the drying agent(s) with the drillcuttings. The drill cuttings may include water-based or non-water basedand/or synthetic additives. Generally, the drying agent has an alkalinepH, a high amount of calcium carbonate and a low pozzolanic activity oris a poor pozzolan. Preferably, the drying agent is not contaminated,such as with organic materials or carbon or containing carbon. Thedrying agent is, in one or more embodiments, one or more of a kilnby-product, such as a cement kiln dust, a lime kiln dust, class F flyash, blast furnace slag, bottom ash, class C fly ash, or similar ash, ornatural hydraulic lime, or caliche, having an alkaline pH. The dryingagent is in an amount between about 1 and about 20% of the quantity ofdrill cuttings. The drying agent in the first combination may also be inan amount between about 1 and about 15% of the quantity of drillcuttings. The drying agent in the first combination may also be in anamount between about 5 and 10% of the quantity of drill cuttings, orgreater than about 5% or less than about 10%. No additional water orother ingredients are required in the first combination. In someembodiments, water is not added to provide the first combination. Thefirst combination is allowed to rest to reduce its moisture content.Resting may include air drying with or without heat. Resting may be withadded heat or cooling. Resting may take place for a few days, for abouta week or more, especially in the absence of added heat or cooling. Theresting occurs after comingling the components that make up the firstcombination. Resting may include discharging the first combination afterblending. The resting may include allowing the first combination to reston a surface and then drying with or without heat or cooling. Theresting may include initially stacking or laying out the firstcombination on a surface and then air drying with or without heat orcooling. The first combination may be stacked, or may be laid out as abed. Upon resting, the moisture content in the first combination may bereduced by about 10%, or by about 15%, or by about 20%, or by about 25%,or by about 30%, or by about 40%, or by about 50%, or by more than 50%,or by about 60%, or more than 60%. By reducing the moisture content, thefirst combination has been dried from a first state to a second state,the first state having more moisture than the second state. In someembodiments, the second state may be a friable state. The second statemeans that the mixture is less cohesive. In some embodiments, the secondstate may be considered to be particulated, said particulates preventedfrom forming a much larger cohesive mass or aggregated mass, thus whenforced together, said particulates generally fall apart. Only afterreaching said second state are additional components added, whendesired. In some embodiments, the stabilized material may be used and/orusable upon achieving the second state. In some embodiment, thestabilized material may be used and/or is usable after includingadditional components to materials that have achieved the second state.Said additional components may include at least a binder, which, whencombined with the first combination in the second state, forms a secondcombination. The second combination may be ready for use or may includefurther molding and/or manipulation. The second combination is in one ormore embodiments, a stabilized material; it may be considered aremediated material and/or deemed a recycled material for reuse. Thesecond combination may be useful after addition of water, whenre-hydrated. The second combination does not generally form a largercohesive or solidified mass without addition of water. In one or moremethods, the first combination is prepared first, followed by preparingof the second combination, the second combination is then hydrated, andwhen re-hydrated is capable of being further shaped into a desiredshape. After hydration, the second combination will solidify and have asolidified matrix. The second combination may take the shape of a bed ora pallet at a desired thickness. The second combination may beintroduced into a mold or a cavity or a space and take on the shape ofsaid mold or cavity or space (in whole or in part). The secondcombination may form one or more layers or become a part of a pluralityof layers.

In some embodiments, either or both the first and second combinationsare prepared near the location from where the drill cuttings wereobtained. In some embodiments, either or both the first and secondcombinations (before or after hydration) are transported to a desiredlocation by pipe or other means, such as a truck or container or thelike. In some embodiments, either or both of the first and secondcombinations are stored before use.

In one or more embodiments, the first combination is prepared byintroducing the components of the first combination, in parallel or inseries, with a first mixing unit and blending or comingling saidcomponents using the first mixing unit. Similarly, the secondcombination is prepared by having the first combination (when in asuitable or desired reduced moisture, the suitable or desired secondstate) and at least one binder and introducing a second mixing unit andallowing the second mixing unit to operate, thereby forming the secondcombination. Both the first mixing unit and the second mixing unit maybe the same type of unit or may be the exact same unit, or may bedifferent units for blending. Suitable examples of mixing units includea pug mill as well as other units for blending, such as ones containingan auger screw; said units known to those of skill in the art forblending, including the blending of aggregates or road base materials. Afirst and/or second mixing unit may also include a skid steercomprising, for example, a bucket and/or mixer. Either or both the firstmixing unit and the second mixing unit may also be one that encloses atleast some of the components and/or is capable of heating or cooling,introducing a temperature to one or more of the components. Either orboth of the first and second mixing units may also have an outputcontainer for collecting and/or holding, the output container may alsobe from which moisture may be removed and/or collected. Either or bothof the first and second mixing units will have an output member orregion from which the blended material is discharged after comingling orblending.

In one or more embodiments, the first combination is prepared byproviding the components of the first combination (i.e., drill cuttingsand a drying agent), in parallel or in series, on a surface or in acontainer having at least one supporting surface. The supporting surfacemay, in some embodiments, be or include soil (sediment, moraine, sand,clay, gravel, etc.) or rock (shale, clay, chalk, limestone, sandstone,igneous rock, etc.) or a binder (cementitious, asphalt, etc.,solidified, partially solidified, or not yet solidified) and variouscombinations thereof. Upon providing said components on the surface, thecomponents are blended or comingled by introducing a first mixing unitas a first mixer, in a first mixing. Similarly, the second combinationis prepared by providing at least one binder, such as a hydraulicbinder, to surface of or comingled with the first combination (when in asuitable or desired reduced moisture, a suitable or desired secondstate). Upon providing said binder, such as an hydraulic binder, on saidsurface of the first combination, blending or comingling by introducinga second mixing unit as a second mixer, in a second mixing, therebyforming the second combination. Both the first mixer and the secondmixer may be the same type or may be the exact same, or may bedifferent. Suitable examples of mixers include those described herein,including ones containing blades, one or more buckets, an auger screw,one associated with a skid steer or any other that may be used forblending aggregates for road base materials, as examples. Either or boththe first mixer and the second mixer may also be capable of heating orcooling or introducing a change in temperature when comingling orblending. Either or both of the first and second mixers may also have anoutput container or region for providing the second combination, and/orfor collecting and/or for holding and/or from which moisture may beremoved and/or collected therefrom. Either or both of the first andsecond mixers will have an output member or region from which theblended material may be discharged after blending. Various options forsaid mixers include but are not limited to belt feeders, buckets, screwfeeders, silos, belt scales, proportioning systems, water systems,movers, conveyors, control houses, and generators.

Said methods do not require pre-treatment of the drill cuttings. Saidmethods do not require but may include a separation step of the drillcuttings, in which components of the drill cuttings are physicallyseparated or run through one or more screens. Said methods do notrequire a scrubbing system or scrubbing step. Said methods also do notrequire drilling any of the components of the first combination orsecond combination into a bore hole after retrieving the drill cuttings.Instead, said methods (and the materials that are produced therefrom)can be performed at any time on drill cuttings retrieved from a drillsite. Said methods (as well as the materials produced therefrom) may beperformed at the same location or very near a drill site location or maybe removed from the drill site location, the methods performed at anytime after retrieval of the drill cuttings.

The methods described provide stabilized materials that are stabilizedand/or recycled materials. Said materials are dried materials that maybe solidified. In one or more embodiments, the stabilized material willinclude a quantity of drill cuttings requiring stabilization and/orrecycling and a drying agent. The drying agent is generally in an amountbetween about 1 and about 20% of the quantity of drill cuttings. In thestabilized material, the drying agent may also be in an amount betweenabout 5 and about 10% of the quantity of drill cuttings. With thecombination of drying agent and the quantity of drill cuttings, thestabilized material will have a reduced moisture content (second state)which is less than the original moisture content in the quantity ofdrill cuttings prior to addition of the drying agent and is less thanthe combination of drying agent and drill cuttings when first introduced(first state). In some embodiments, the moisture content of theremediated material is significantly less than its original moisturecontent (prior to addition of the drying agent). In some embodiments,the drying agent is one having an alkaline pH, a high amount of calciumcarbonate and a low pozzolanic activity (is a poor pozzolan). In someembodiments, the drying agent is kiln dust or ash or similar by-product(calcined or thermally decomposed) having an alkaline pH greater thanabout 9 or about 10 or more.

The methods described also provide a stabilized material that includes aquantity of drill cuttings, e.g., requiring remediation, comingled witha drying agent, and at least a binder, such as hydraulic binder. Thebinder is incorporated only after the quantity of drill cuttings hasachieved a second state in the absence of water or without the additionof water, and having first been combined with the drying agent andtransformed from a first state to a second state, said second statehaving a reduced moisture content, less than the moisture content of theoriginal drill cuttings (i.e., prior to addition of the drying agent) orless than the moisture content of the first state. The second state is aless-cohesive state, and, in some embodiments, includes a state thatprevents a larger mass from forming. In some embodiments, the secondstate is provided as a particulated state, in which said particulatesare prevented from forming a much larger aggregated or a cohesive mass.In some embodiments, the second state has less than the optimum moisturecontent for compaction (e.g., as specified by the American Associationof State Highway and Transportation, T-99). The binder is, as anexample, an alkaline hydraulic and/or cementitious binder havingpozzolanic activity. The hydraulic binder as a good pozzolan, when addedto the combination of the drill cuttings and drying agent in the secondstate, will undergo a hydraulic reaction when hydrated, and willthereafter solidify. The hydraulic binder may be blended prior to orafter hydration. Hydration may occur at once or in doses. Hydration isrequired for solidification of the second combination; however,solidification generally requires a hydraulic binder comingled with thesecond combination since the drying agent is not considered a pozzolanor a good pozzolan.

Further described is a system for providing a stabilized material, thesystem comprising a first mixing unit for providing a first combinationthat includes a quantity of drill cuttings requiring stabilization. Thesystem also includes a drying agent, as previously described, forblending with the quantity of drill cuttings. In addition, the systemincludes a second mixing unit for blending output of the first mixingunit with a hydraulic binder. Suitable examples of mixing units asmixers include but are not limited to standard mixer, a pug mill, aswell as other means for blending, such as mixing means containing one ormore blades, or an auger screw; said units or mixing means known tothose of skill in the art for blending, including the blending ofaggregates, hydrated binders, and/or road base materials.

Still further is a method of preparing a stabilized material. The methodincludes combining a drying agent and a quantity of drill cuttings toform a first combination, the quantity of drill cuttings having amoisture content between about 1% and about 45%, the drying agent in thefirst combination being in an amount between about 1% and about 20%based on a weight of the drill cuttings, the drying agent causing thefirst combination to achieve a first state having a moisture contentless than the moisture content of the drill cuttings. The methodincludes causing the first combination to achieve a second state, thesecond state including a reduced moisture content as compared with themoisture content of the first state, the reduced moisture content beingat least 20% less than the moisture content of the drill cuttings. Themethod includes combining the first combination in the second state withat least one surface acting agent, thereby forming a second combination,the second combination forming the stabilized material. The drying agentmay be at least one of a kiln dust, and ashable by-product of analkaline material. The drying agent may be alkaline and a by product ofa calcination reaction. The drying agent may be in an amount betweenabout 5% and about 12% based on the total weight of the firstcombination. The method may further comprise hydrating the secondcombination. The method may further comprise combining utilizes a mixer.The method may include combining the second combination with at leastone hydraulic binder and water. In the method, causing includes thefirst combination achieving a second state includes stacking and airdrying for at least seven days. The method may further comprise removingat least a portion of drilling mud from the drill cuttings beforecombining with the drying agent. The moisture content of the drillcuttings may be between about 5 and about 15%.

In additional embodiments a stabilized material is described herein. Thestabilized material comprises a quantity of drill cuttings requiringstabilization. The quantity of drill cuttings may have moisture contentbetween about 1 and about 45%. The stabilized material comprises adrying agent. The drying agent may be in an amount between about 1 andabout 20% based on a weight of the drill cuttings. The stabilizedmaterial comprises at least one surface acting agent. The at least onesurface acting agent may be incorporated only upon combining thequantity of drill cuttings and the drying agent and achieving atransition in moisture content from a first moisture state to a secondmoisture state, the second moisture state less than the first moisturestate, a second moisture state having a moisture content that is atleast about 20% less than the moisture content of the drill cuttings.The drying agent may be in an amount between about 5 and about 10% ofthe quantity of drill cuttings. The drying agent may be a kiln dust. Thedrying agent may be alkaline and a by product of a calcination reaction.The stabilized material may further comprise a hydraulic binder andwater. The stabilized material may further comprise water, the waterbeing introduced only after achieving the transformation. The dryingagent is a poor pozzolan.

In still further embodiments is described a system for providing astabilized material. The system comprises drill cuttings having amoisture content of between about 1 and about 45%. The system comprisesa first mixing unit for providing an output as a first combination whenintroducing a quantity of drill cuttings with the first mixing unit. Thesystem comprises a drying agent for combining with the drill cuttings,the drill cuttings having an amount of about 20% based on the weight ofthe drill cuttings. The system comprises a second mixing unit forintroducing the first combination with at least one surface actingagent. The first mixing unit and second mixing unit may be the same. Thefirst mixing unit and the second mixing unit may be different. The firstmixing unit may be a skid steer comprising a mixer and the second mixingunit may be an auger screw. The system may further comprise a containerfor storing the first combination. The system may further comprise areceiving unit for receiving output from the second mixing unit. Thereceiving unit may be selected from the group consisting of piping,tubing, pallet, sheet, pit and combinations thereof. The drying agentmay be a kiln dust.

These and other embodiments and features and the advantages thereof,will become readily apparent from the following description, taken inconjunction with any exemplary representations, drawings and/orexamples.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the description provided herein andthe advantages thereof, reference is now made to the brief descriptionbelow, taken in connection with the accompanying drawing and detaileddescription.

FIGS. 1A-1C depict representatively methods for providing a firstcombination as described herein;

FIG. 2 depicts initial drill cuttings when aggregated as describedherein;

FIG. 3 depicts a representative first output as a first combination in asecond state as described herein;

FIG. 4 depicts further representative processes described herein;

FIG. 5 illustrates a relationship between compressive strength and anamount of hydraulic binder provided with a known quantity of drillcuttings;

FIGS. 6-8 depict still further representative processes describedherein; and

FIG. 9 illustrates a second combination described herein aftercompaction.

DETAILED DESCRIPTION

Although making and using various embodiments are discussed in detailbelow, it should be appreciated that as described herein are providedmany inventive concepts that may be embodied in a wide variety ofcontexts. Embodiments discussed herein are merely representative and donot limit the scope of the invention.

Described herein are systems and methods of making stabilized and/orrecycled materials and the materials themselves. The stabilized and/orrecycled materials are suitable for re-use, such as a sub base, meetingperformance criteria and/or standards for a sub base or as a sandy,non-plastic road material. The stabilized and/or recycled materials aresuitable for re-use, such as a sub grade road material, meetingperformance criteria and/or standards for a sub grade road material. Thestabilized and/or recycled materials provided herein may be on-siterecycled materials that are stabilized in accordance with State andFederal road and highway requirements and suitable for use as a roadmaterial. The stabilized and/or recycled materials may be deemed asnon-hazardous recycled materials for re-use. The stabilized and/orrecycled materials will include drill cuttings that requirestabilization, due to the fact that the drill cuttings contained anamount of contaminant or pollutant requiring stabilization.

The drill cuttings requiring stabilization may include drill cuttingsthat have or have not been separated from the drilling mud or drillingfluids; the drilling mud may be synthetic, aqueous based or non-aqueousbased. With or without separation of drill cuttings from drilling mud,drill cuttings will have fines and course aggregate saturated withmoisture, the moisture derived at least in part from the drilling mud.Such drill cuttings may also be referred to as aggregated drillcuttings. It is not uncommon for said drill cuttings to contain, evenafter separation, about 5 to about 10% moisture, or about 5 to about 15%moisture, or about 5 to about 40% moisture, or about 1 to about 45%moisture, or up to about 15% moisture, or up to 20% moisture, or up to25% moisture, or up to 30% moisture, or up to 35% moisture, or up to 45%moisture, and from about 5 to about 25% hydrocarbons (e.g., diesel, oil,and other hydrocarbon sources), or about 5 to about 15% of saidhydrocarbons. Of course other ranges therein and amounts are possible.The hydrocarbon fraction as well as the non-hydrocarbon fractions willoften contain other potential contaminants or pollutants. With themethods described herein moisture is initially removed from the drillcuttings and without being bound by theory, said initial moistureremoval is integral in allowing the stabilization and re-use describedherein, including providing said material with the described structuralintegrity; said methods include, in addition to moisture removal,removal and/or stabilization of hydrocarbons and other contaminants fromwithin the drill cuttings. Hydrocarbons are, thus, believed to be notonly contained by said methods and systems, also to be removed at leastin part from the drill cuttings. Additional potential contaminants orpollutants in the drill cuttings include metals (e.g., chromium, copper,cesium, nicked, lead, barium and zinc, as representative examples) aswell as contaminating salts, chlorides, or chlorine, as examples. Theseadditional potential contaminants or pollutants are also containedand/or controlled by the methods described herein.

With said methods, the drill cuttings are initially combined with one ormore drying agents. The drill cuttings do not require any furthermodification prior to initially combining with the one or more dryingagents. For example, prior to initially combining with the one or moredrying agents the drill cuttings do not need to be thermally treated.The drill cuttings do not need to be further subjected to processes thatliberate gases and/or evaporate liquids prior to initially combiningwith the one or more drying agents. The drill cuttings do not need to befurther screened prior to initially combining with the one or moredrying agents. The drill cuttings do not need to be further milled priorto initially combining with the one or more drying agents. The drillcuttings do not need to be formed into a fine powder prior to initiallycombining with the one or more drying agents. The drill cuttings do notneed to be compressed and/or pelletized prior to initially combiningwith the one or more drying agents. The drill cuttings when combinedwith the one or more drying agents are generally provided as wet drillcuttings or as mud-like or as slurry-like aggregated drill cuttings.

In some embodiments, the drill cuttings may be initially screened toremove drilling mud (or a portion thereof) in processes known to thoseof skill in the art (e.g., conveying on shakers with screens forrecycling at least a portion of the mud). In some embodiments, thedrilling mud has been at least partially removed from the drillcuttings, which offers an opportunity for the drilling mud to berecycled. In some embodiments, one may further subject the drillcuttings or at least a portion of the drill cuttings to a grinder thatreduces the size of at least some of the aggregates in the drillcuttings prior to initially combining with the one or more dryingagents. In some embodiments, it may be preferred that a portion of theaggregates in the drill cuttings are larger than another portion of thedrill cuttings. This combination of larger and smaller sized aggregateswill, in some embodiments, increase the overall strength of the finalmaterial produced, which includes material formed by the methodsdescribed herein and/or when solidified. Having a combination of largerand smaller sized aggregates allows a lock-in fit with the differentsized aggregates and between the different sized aggregates, providingless gaps between aggregates when later formed as a re-used and/orsolidified material.

The drying agent will have an alkaline pH, a high amount of calciumcarbonate and a low pozzolanic activity. In some embodiments, the amountof calcium carbonate is greater than about 40 wt. %. In someembodiments, the amount of calcium carbonate is greater than about 50wt. % or is greater than about 60 wt. % or is greater than about 70 wt.% or is greater than about 80 wt. % or is greater than about 90 wt. %.The calcium content may be contained in a combination of calciumcarbonate and/or calcium oxide. The drying agent has, itself, only avery low or even negligible amount of moisture and is capable ofmoisture absorption. In some embodiments, the drying agent will haveonly a low or very low amount of crystalline silica. In manyembodiments, the amount of crystalline silica is from 0 to about 10 wt.%. In some embodiments, the amount of crystalline silica is less thanabout 10 wt. %, or is less than about 9 wt. %, or is less than about 8wt. %, or is less than about 7 wt. %, or is less than about 6 wt. %, oris less than about 5 wt. %. In some embodiments the amount ofcrystalline silica is negligible, or is from about 0 to about 5 wt. % oris from about 0 to about 4 wt. %, or is from about 0 to about 3 wt. %,or is from about 0 to about 2 wt. %, or is from about 0 to about 1 wt.%. In some embodiments, the drying agent will have an amount of silicondioxide that is less than or is a lot less than other ashes (combustionby products), such as Class F fly ash, blast furnace slag and bottomash. In some embodiments, the drying agent will be an ash with a loweramount of silicon dioxide. A representative examples of a drying agentis kiln dust or at least partially calcined kiln feed which is removedfrom and collected, for example, in a dust collector during themanufacture of cement or lime. In one or more forms the kiln dust iscement kiln dust or lime kiln dust. Preferably the cement kiln dust whenused is from the manufacture of Type I Portland cement. Otherrepresentative examples of a drying agent include but are not limited tostacking dust and lime, each having an alkaline pH. Class C fly ashhaving a much reduced silicon dioxide amount (e.g., when not consideredpozzolanic, not considered a strong cementitious reactant) may also beused. Still further, the drying agent may be or may include calichepreferably in powdered or particulated form, which typically has acalcium carbonate content of about or greater than about 70% or 80%.Still further, the drying agent may be or may include natural hydrauliclime in powdered or particulated form.

The drying agent is introduced generally as a fine particulate material.The particulates will have a size in a range from about 0.5 microns toabout 800 microns and generally less than about 1000 microns. Variousranges therein may be provided, without limitation when desired. Suchranges may include but are not limited to 0.5 microns to about 10microns or from about 0.5 microns to about 20 microns or from about 1micron to about 100 microns or from about 20 microns to about 200microns or from about 100 or about 200 microns to about 800 or about1000 microns or from about 20 microns to about 500 microns or from about100 microns to about 1000 microns.

When more than one drying agent is introduced, overall properties of theone or more drying agent will be such that, in total, the amount ofcalcium oxide is greater than as described above (e.g., greater thanabout 40 wt. %). In addition, in total, the moisture content of the oneor more drying agents will be very low or even negligible. In total, theone or more drying agents will be capable of moisture absorption.Moreover, in total, the amount of crystalline silica in the one or moredrying agents should not be more than about 10 wt. %, or the totalamount of crystalline silica will be less than about 10 wt. %.Similarly, in total, the drying agent(s) should not be considered strongpozzolans, or agents considered to behave as a strong cementitiousreactant.

When the one or more drying agent is initially introduced to theaggregated drill cuttings, the combination with drill cuttings isgenerally considered to be in a first state. The first state isgenerally depicted as having a moisture content defined primarily asbeing dryer than or having a moisture content that is less than that ofthe drill cuttings. Thus, the moisture content of the first state may befrom about 1 to about 10%, or from about 5 to about 15%, or from about 5to about 40%, or from about 1 to about 40%, or from about 1 to about45%, or up to about 15%, or up to 20%, or up to 25%, or up to 30%, or upto 35%, or up to 45%. Collectively, the drying agent(s) and the drillcuttings together form a first combination.

The amount of drying agent(s) introduced with the drill cuttings mayrange from about 0.5% to about 20% of the quantity of drill cuttings, orin any various range therein. For example, the drying agent(s) may be inan amount (based on weight of drill cutting) ranging from about 3% toabout 15% or from about 5% to about 10%, or from about 5% to about 15%,or up to about 10%, based on the quantity (by weight) of the drillcuttings.

Generally, the one or more drying agent is combined with the drillcuttings using a unit for blending, such as a mixer, blender, blendingdevice or other similar unit or means for blending that is known in theart for blending or combining aggregate materials. A suitable example isa pug mill having a hopper or feed assembly through which the dryingagent and the drill cuttings are fed. Another example is a unit ormachine comprising an auger screw. A further example is a skid steercomprising at least a mixer or mixing unit. Said machinery may becentrally stationed or may be local, such as near a drilling site, andone or more may be moveable and/or portable. In some embodiments, thedrill cuttings and drying agent(s) are introduced into the unit forblending; this may be done in series (with no particular order) asrepresented with FIG. 1A or simultaneously as represented with FIG. 1B.In some embodiments, the one or more drying agent(s) are introduced withthe drill cuttings (in no particular order) and then the unit forblending is introduced as represented with FIG. 1C. After combining thedrill cuttings with the drying agent (through utilizing the unit ofblending) an output is formed also referred to as a first combination.With any of FIGS. 1A-1C, the drill cuttings (boxes 1, 5, 7) and dryingagent(s) (boxes 2, 4, 7) are introduced, and comingled via the unit ofblending to form said output or first combination (boxes 3, 6, 9). Thisis also depicted in FIG. 4 , box 10.

In some embodiments, the combining (blending or comingling) of thecomponents described herein, which includes the one or more drying agentand the aggregated drill cuttings, may be performed at an ambienttemperature. In addition, in some embodiments, the unit of blending orutilizing the means for blending may include a heater or coolercompartment or means for heating or cooling, so that the methodsdescribed herein include one or more steps of heating and/or cooling.Said heating and/or cooling may, depending in part on the configurationand means for heating or cooling, be performed prior to, during and/orafter blending. As such, the one or more steps of heating and/or coolingmay take place prior to forming the first combination, at the time offorming the first combination or after forming the first combination,when a temperature change is desired or is necessitated. As depicted inFIG. 4 , upon forming a first combination in a first state (box 10),there is a subsequent causing of the first combination to achieve asecond state (box 12). Causing the first combination to achieve thesecond state may also occur prior to, during or after heating and/orcooling, when a temperature change or temperature changes are desired orare necessitated. For example, in some embodiments, combining (blendingor comingling) of the one or more drying agent and the aggregated drillcuttings to form the first combination, as depicted in FIG. 4 , box 10,will be performed at or near the same temperature as the temperature ofthe components or at or near the same temperature as the ambienttemperature. This may include a small change in temperature between theinitial temperature of the components and the temperature duringblending, such as about 20 degree (F.) (or about 11 degree C.) or lessthan 20 degree (F.) (or about 11 degree C.) difference between theinitial temperature of the components and the temperature duringblending. There is often no more than about 20 degree (F.) (or about 11degree C.) difference between the temperature of the components and thetemperature during blending.

With any further addition of heat (when desired, and which may occurprior to, during or after blending), it will always be at a temperatureless or much less than a temperature used to thermally cure a hydraulicmaterial (e.g., less or much less than about 140 degrees C.). Withcooling (hen desired, and which may occur prior to, during or afterblending), the temperature will always be a temperature that does notpromote freezing. In some embodiments, cooling temperatures assist whenoutside temperatures are very high. For example, cooling temperaturesmay be applied to reduce the temperature after blending, such as to keeptemperatures near or within about 20 degrees of the initial temperature(e.g., prior to the blending).

Output after blending (e.g., FIGS. 1A-1C, boxes 3, 6, 9, and FIG. 4 ,box 10) utilizing the unit for blending will have a reduced moisturecontent, less moisture than the amount of moisture in the initial drillcuttings. The output may initially have a reduced overall density (lessdensity than that of the initial drill cuttings) with the reduction inmoisture content. Without being bound by theory, the drying agent(s)essentially remove an amount of moisture and assist, therefore, inremoving and/or reducing overall moisture contained in the aggregateddrill cuttings, the moisture in the drill cuttings containing aqueous ornonaqueous hydrocarbons and other potential contaminants. Thus, whilethe initial aggregated drill cuttings include large aggregated masses orwere provided as an aggregated slurry, with the moisture reductiondescribed herein, the material formed as output (when utilizing theprocesses described herein) will be provided as a plurality of moreindividualized particulates. FIG. 2 illustrates representative examplesof large aggregated masses 11 as can be found with initial drillcuttings. FIG. 3 illustrates representative individualized particulates15 from the plurality of individualized particulates as found withoutput after comingling or blending the large aggregated masses (drillcuttings) with the drying agent(s) described herein.

As such, as described herein, output after blending, such as describedwith FIGS. 1A-1C (e.g., boxes 3, 6, 9) is considered a particulatedoutput as compared with the large aggregated masses or the aggregatedslurry of the initial drill cuttings.

Moisture reduction and/or removal described herein, as depicted in StageA, FIG. 4 , preferably includes a two step process for reduction and/orremoval of moisture contained within and/or bound within the aggregatedcomponents of the drill cuttings of FIGS. 1A-1C (boxes 1, 5, 7) thathave an inherent porosity, said aggregated components of the drillcuttings having been aggregated into the larger masses and/or providedas the aggregated slurry. Upon reduction and/or removal of the moisturebound or within said initially aggregated components of the drillcuttings, at least a portion of the hydrocarbons as well as othervolatile components contained in said moisture are freed up, such thatthe contaminants and volatiles are now capable of release, in part, byevaporation, or of breaking down, such as via oxidation. Such acondition, which includes the reduction and/or removal of moisture, isconsidered, in some embodiments, a transition of the output or firstcombination from a first state (FIG. 4 , box 10) to a second state (FIG.4 , box 12).

Optimum reduction in moisture content is achieved when the output afterblending utilizing the unit for blending is allowed to rest for a periodof time. Thus, in some embodiments, the output having the reducedmoisture content is obtained when the first combination has a reducedmoisture state with a desired reduction in moisture content, or hasachieved the desired reduction in moisture content in the second state.The reduction in moisture content includes a reduction in moisture ascompared with the initial drill cuttings, and may include a transitionin moisture level or moisture content from a first state to a secondstate, as depicted in boxes 10 and 12 of FIG. 4 . The second state willhave a reduced moisture content as compared with the first state. Thereduced moisture content in the second state is less than the moisturecontent in the first state. This reduction (from initial drill cuttingsto second state) may be about 20 wt. % reduction in moisture content, ormay be about 25 wt. % reduction, or may be about 30 wt. % reduction, ormay be about 35 wt. % reduction, or may be about 40 wt. % reduction, ormay be about 45 wt. % reduction, or may be about 50 wt. % reduction, ormay be greater than 50 wt. % reduction, or any range therein, in whichthere is generally at least a 20 wt. % reduction in moisture content inthe second state as compared with the moisture content in the initialdrill cuttings. Because of the low pozzolanic activity of the dryingagent(s), the output (i.e., when the drying agent(s) is comingled withthe drill cuttings) will not solidify (e.g., will not solidify at afirst state or at a second state).

To cause the first combination to achieve the second state, the outputmay rest at an ambient temperature or at a higher than ambienttemperature. The higher temperature should be less than a temperaturethat is used to thermally cure a hydraulic material (e.g., less or muchless than about 140 degrees C.). The higher temperature may besufficient to completely or nearly completely dry the output, therebylessening the time for resting. The higher temperature may be achievedby introducing additional heat to the output. If output is allowed tosimply rest, the rest period may be about 24 hours or at least 30 hoursor about 72 hours, or at least a few days, or up to a week, or may begreater than a week. The rest period may also be at least for a week(e.g., at least about seven days), or may be more than a few weeks. Insome embodiments, the output may simply rest (generally withoutintroducing additional heat) for some period of time before further use.This period of time may be about at least five days to ten days fordrill cuttings obtained from a drill hole and provided as an output. Insome embodiments, the rest period may be at least about seven days foroutput that originated from a drill or well hole. Longer periods areeffective as well. There does not appear to be a detrimental effect whenthe output rests for longer periods. The output when caused to achievethe second state remains particulated, considered (using jargon) to becrumbly, and is no longer aggregated in the large aggregated masses oras an aggregated slurry. The output when in the second state, does notsolidify on its own and does not readily aggregate (form a largercohesive mass) on its own. For example, the output when in a secondstate does not re-aggregate into large aggregated masses, such as whenthe particulates of the second state are pressed together by hand.Achieving the second state provides a composition with structuralintegrity and strength. Thus, when the first combination in the secondstate is used (FIG. 4 , box 32; FIG. 6 , box 612; FIG. 7 , box 712) oris further formed to provide a final composition (FIG. 4 , boxes 14-30;FIG. 6 , boxes 614-622; FIG. 7 , boxes 714-724), there is a structuralintegrity and strength that is achieved. This differs from alternativeprocesses in which the described second state, which occurs as depictedin FIG. 4 , Stage A (also in FIG. 6 , boxes 610-612; FIG. 7 , boxes710-712), is not achieved.

In one or more embodiments, the second state is a friable state. In oneor more embodiments, the output after blending, when in a second state(with a period of rest), is a particulated output and will not on itsown form a molded cohesive mass, such as, for example, when a quantityof the output is gently pressed together (e.g., by hand). In one or moreembodiments, the output in a second state is when the moisture contentis less than optimum moisture for compaction (e.g., in accordance withthe American Association of State Highway and Transportation Officials(AASHTO), T-99 or T-180). In some embodiments, the output is best in asecond state when the moisture content is about 3 to about 5 percentagepoints less than optimum moisture content for compaction (e.g., inaccordance with the AASHTO T-99 or T-180). In some embodiments, theoutput in a second state is when the moisture content is more than about5 percentage points less, or more than about 6 percentage points less,or more than about 7 percentage points less, or more than about 8percentage points less, or more than about 9 percentage points less, ormore than about 10 percentage points less, or from between about 8 andabout 10 percentage points less than optimum moisture for compaction,such as in accordance with AASHTO T-99 or T-180.

In view of the methods described herein, reduction in moisture (e.g.,reduced moisture content) of the drill cuttings is due in part fromevaporation. Reduction in moisture is due in part from absorption. Somemoisture reduction may also be due in part from drainage. The drainedmoisture, however, will not typically contain an amount of contaminantor pollutant that must be contained or further treated. When desired, ameans for collecting the drained moisture is also acceptable and may beincluded with the described method.

The output, which, when caused to form a first combination in a secondstate, has a reduced moisture content from that of the aggregated(initial) drill cuttings and is a stabilized material, as depicted inFIG. 4 , box 32. The output, when formed as a first combination in asecond state will have a reduced moisture content from that of theaggregated (initial) drill cuttings and is a recycled material that issuitable for re-use. With the processes described herein, the initialdrill cuttings transition from a moisture bound state (initial state) toa first state (FIGS. 1A-1C) and are caused to transition to a suitablereduced moisture state (second state; FIG. 4, 6, 7 ) to provide thestabilized material and/or the recycled material. As an example, whenthe moisture bound state of the initial drill cutting (e.g., provided asaggregated drill cuttings or as the aggregated slurry), as previouslydescribed, includes up to about 15% moisture after drilling. The reducedmoisture state, as described herein, and after introducing andincorporating the drying agent(s) in the manner and quantity describedherein, may have a total moisture content of less than about 12% in thesecond state, which is a reduction of about 20% in the total moisturecontent. The total moisture content in the reduced moisture state(second state) may also be less than about 10%, which is a reduction ofabout 33% in moisture from the moisture content in the initial drillcuttings. In some embodiments, the reduced moisture state may be about25% or less, or about 20% or less, or less than about 20%, or less thanabout 19%, or less than 18%, or less than 16%, or less than 15%, or lessthan 14%, or less than 13%, or less than 12%, or less than 11%, or lessthan 10%, or less than 9%, or less than about 8%, or less than about 7%,or less than about 6% or less than about 5%, or may be from about 3% toabout 8%, or from about 5% to about 12%, or from about 5% to about 20%.The latter reduced moisture state shows that the moisture content may bereduced by as much as 66% or even greater than 66% by methods describedherein. In some embodiments, the reduced moisture state as describedherein will have moisture content that is less than optimum moisturecontent for compaction. In some embodiments, moisture content in thereduced moisture state is at least about 3% less than optimum moisturecontent for compaction. In some embodiments, moisture content in thereduced moisture state is more than 5% less than optimum moisturecontent for compaction. In some embodiments, moisture content in thereduced moisture state is from anywhere between about 6% to 10% lessthan optimum moisture content for compaction. The stabilized and/orrecycled material provided after causing the first combination toachieve a second state, as depicted in box 32, FIG. 4 , is, as describedabove, a particulated material. Said material may be deemed a recycled,non-hazardous material suitable for re-use. Said material may beconsidered a remediated material. This material may be stored or may bere-used as further described below.

For re-use, the stabilized and/or recycled material, that is, thematerial having the reduced moisture state (after utilizing the unit ofblending with output therefrom forming the first combination and thencausing the second state), may be a stabilized and/or recycled materialsuitable as a sub base or a sandy, non plastic material, meeting theperformance criteria of a sub base or a sandy, non plastic material. Forexample, said stabilized and/or recycled material can have a compressivestrength of between about 25 to 100 psi, or may have a compressivestrength of at least 35 psi for use as a sub base or as a sandy, nonplastic material.

For re-use, the stabilized and/or recycled material, that is, thematerial having the reduced moisture state (after utilizing the unit ofblending with output therefrom forming the first combination and thencausing the second state), may be used after achieving the second state.This final material as described herein may have a compressive strengththat is at least about 35 psi. Said final material having a compressivestrength of at least 35 psi is suitable for use as a sub base roadmaterial or as a sandy non plastic road material.

In additional embodiments the material having the reduced moisture state(second state) may be further blended with one or more additionalcomponents (e.g., FIG. 4 , boxes 14, 20, 24, 26). Introduction of theone or more additional components occurs after the first combination isin the second state, meaning the moisture content has been reduced fromthe initial state (drill cuttings) and from the first state (firstcombination), or has completed Stage A, as depicted in FIG. 4 . Onerepresentative additional component is a binder or at least one bindingagent, such as a hydraulic binder or non-hydraulic binder (with orwithout additional components, such as fillers, fibers, additives,etc.). In addition or as alternative, another representative additionalcomponent that may be included is a surface acting agent withcharacteristics of a surfactant that lowers the surface tension. Thesurface acting agent may be provided as a detergent, dispersant, wettingagent, and/or emulsifier, foaming agent. The binder and/or surfaceacting agent (in addition to other added components) may be provided inno particular order in Stage B (see, e.g., FIG. 4 ).

With introduction of the additional components, such as binder(s) and/orsurface acting agent(s), re-wetting of the first combination (in thesecond state) is necessary in order to form a second combination thatwill solidify (e.g., FIG. 4 , boxes 16, 22, 28; FIGS. 6-7 ). Thus, acomponent having some moisture (aqueous or non-aqueous or combinationthereof, such as an emulsion) is introduced to the first combinationwhen in the second state. Re-wetting may occur either prior to, duringor after introduction of the additional components, such as binder(s)and/or surface acting agent(s). Re-wetting may include a re-hydration ofcertain components, such as when solidification involves a hydrationreaction. Water or an aqueous liquid or solution will, in someembodiments, be added in addition to the binder (either together in amixture or independently, before, or after) in the re-wetting phase.Re-wetting may include a melting, digesting or cooking of componentsfollowed by hardening and/or curing of components. The binder mayinclude a non-aqueous liquid or solvent or melt, or an emulsion ordispersion, in some embodiments, in which the binder is generallyintroduced with the non-aqueous liquid or solvent or melt, or as anemulsion or dispersion, such that the binder is in amixture/emulsion/dispersion/melt, although in some instances, the bindermay be provided independently, or provided before, or after additionalcomponents. Addition of any one or more of the binder with or withoutadditional components provides a second combination (e.g., FIG. 4 , box30). The second combination when formed (e.g., solidified) is also astabilized and/or recycled material, suitable for use. Thus, asdescribed herein, output as the first combination in the second state,when further blended with at least binder(s) and/or surface actingagent(s), forms the second combination, requiring re-wetting tosolidify, as depicted in FIG. 4 , Stage B, boxes 14-28.

A second combination having the one or more additional components, suchas binder(s) and/or surface acting agent(s), is required to form asolidified stabilized and/or recycled material. For hydration reactions,re-wetting or re-hydration includes a transition from the reducedmoisture state to a wetted state, which occurs before solidification.This described process is contrasted against preparations disclosed byothers, in which their output after blending, even when performed with aso-called drying agent, does not provide a comparative combinationhaving a reduced moisture content as described herein, and therefore,has instead a higher moisture content than what is described herein.Said alternative preparations do not disclose transitioning from a firststate to a second state, in which the second moisture state is a driedor a friable state. The reduction in moisture content described hereinto a dried or friable state ensures adequate stabilization and/orsolidification thereafter. In preparations disclosed by others that donot cause the transition from the first state to the second state,moisture of these so-called comparative combinations will already havemoisture content that is several percentage points higher than theoptimum moisture content for compaction (e.g., in accordance with AASHTOT-99 or T-180), meaning that these other so-called comparativecombinations (those disclosed by others) will start with have a highermoisture content in said preparations that are going to be solidified.

As described herein, when fully blended as the second combination, afinal material (e.g., a stabilized and/or recycled material for re-use)will have been or will undergo re-wetting (re-hydration or re-moisteningor melt before undergoing a solidification reaction, such as a curing,hardening, hydration reaction, hydraulic reaction, and/or non-hydraulicreaction, thermal decomposition, evaporation, etc.) As long as at leastone binder (with or without additional components, such as surfaceactive agent(s), fillers, fibers, polymers, additives, etc.) isintroduced in the manner described herein with or in a re-wetting step(such as in Stage B of FIG. 4 , or after box 12 of FIG. 4 , or boxes614-622 of FIG. 6 , or boxes 714-724 of FIG. 7 , or boxes 814-820 ofFIG. 8 ) to form the second combination, no further additive is requiredin order for a fully blended final combination as described herein tosolidify. In hydration reactions, the amount of water is provided in anamount typically included for dried components to undergo a hydrationreaction and to solidify. With emulsions, dispersion, or melts or cookedmixtures, the amount of binder may be higher when the particulatesobtained from the first combination in the second stage are small. Afully blended final combination as described herein may undergo furthershaping (e.g., forming as a sheet, forming on a pallet or bed, orotherwise molding or shaping) or may be used as a filling material, suchas in a bore hole or frac hole, or may be laid as a road base material.As a road base material, the stabilized materials described herein maybe laid either before or after re-wetting.

In additional embodiments, when fully blended as the second combination,a final material (e.g., a stabilized and/or recycled material forre-use) will be blended with a binder that hardens or solidifies withoutaddition of water. Such binders are often provided as emulsions. Asdepicted in FIG. 8 , the methods described may also include forming afirst combination from a first state (box 810) to a second state (box812) and adding at least one binder (with or without additionalcomponents, such as surface active agent(s), fillers, fibers, otheradditives, etc.) in which the binder is in a non-aqueous phase (box814), which are combined to form the second combination (box 816).Again, in some embodiment, no further additive may be required in orderfor a fully blended final combination as described herein to solidify,said material when finally formed providing a stabilized and/or recycledmaterial (box 820). The binder is provided in an amount typicallyincluded when undergoing emulsion-type solidification or curing. Whenfully blended, this final combination described herein may undergofurther shaping (e.g., forming as a sheet, forming on a pallet or bed,or otherwise molding or shaping) or may be used as a filling material,such as in a bore hole or frac hole, or may be laid as a road basematerial.

When fully solidified, the final material described herein (e.g., aftersolidification and/or rewetting and curing/hardening) may have acompressive strength that exceeds 150 psi. The compressive strength mayalso be about or greater than about 200 psi. The compressive strengthmay be as high as 400 psi or higher. The compressive strength obtainedis consistent with the compressive strength that is obtained from asolidified hydraulic material formed without the output described herein(that is, without the combination of drill cuttings and one or moredrying agent). Thus, knowing a compressive strength of the binderdescribed herein (in which the binder is a binder material, such as ahydraulic binder) will provide an estimate of the compressive strengthof a final material described herein. For example, FIG. 5 depicts acompressive strength measurement of various amounts of binder materialafter blending with drill cutting and solidifying the binder and drillcuttings, in which the binder was a cementitious binder comprisingPortland cement and was added to the drill cuttings in amounts rangingfrom 4% to 8% by weight of the drill cuttings. The compressive strengthsin FIG. 5 are similar to what would be obtained from a final materialdescribed herein that included the output described herein having beenprocessed as described herein, when said output transitioned from thefirst to second state before blending and re-hydrating with saidcementitious binder. Thus, a final material described herein whensolidified, may, in many embodiments, be readily prepared to meet apredetermined compressive strength. In some embodiments, the finalmaterial when solidified will have, or can be designed to have, acompressive strength that exceeds that of caliche.

In the methods described herein, forming the second combination may beperformed by the same unit for blending that is used to provide thefirst combination, or a second blending unit may be used, in which thesecond blending unit or unit for blending is the same or different or inline. Thus, like the first unit for blending, the second unit ofblending may also be a mixer, blending device, blender or other similarunit or device that is known in the art for blending aggregatematerials. The second unit for blending may, in some embodiments,include a heater or cooler or a compartment for heating or cooling priorto, during and/or after blending. For example, the second unit forblending may be a pug mill having a hopper or feeder into which outputfrom the previous blending (e.g., first combination in the second state)is introduced, in addition to the binder and/or the surface active agentand/or additional components. Said introduction may be simultaneous, inbatches, with or without water, and/or interrupted with additions ofwater. The second unit for blending may be a tiller or an auger-typescrew, or other unit or machine having blades that can blend said firstcombination in the second state with the binder and/or the surfaceactive agent and/or additional components. For example, in someembodiments, the first combination is provided on the ground, or in apallet or on a sheet or on a liner and the binder and/or the surfaceactive agent and/or additional components may be introduced to a surfaceof the first combination in the second state and then further combinedto form the second combination by introducing the second unit ofblending to the same surface that has the first combination thereon. Thecombining may occur before or after the introduction of water.Representative examples are depicted in FIGS. 6 and 7 . These examplesillustrate that the output as a first combination in the second statemay be further blended in or with a unit for blending when introducedwith additional components, at least one of which is binder and/or areactant (reactive binder) that facilitates formation of a hydraulicreaction (e.g., a cementitious reaction) when re-wetted. The at leastone binder, such as the hydraulic binder may be added in dry form,somewhat hydrated or as a slurry (hydrated). Alternatively, the bindermay be in a more melt form, dispersion, and/or emulsion form.

Blending to form the second combination may be performed at an ambienttemperature or may be blended under thermal conditions, in which thetemperature is a temperature below that used to thermally cure thecomponents, or at a temperature that facilitates the hydraulic reaction(which is generally between 120 and 160 or 170 degrees C., and generallynot greater than about 160 or 170 degrees C.) or that facilitates thesolidification reaction.

Suitable binders that serve as hydraulic binders include, but are notlimited to cementitious binders, such as Sorel cement, Portland cement,pozzolana cement, gypsum cement, high alumina content cement, slagcement, silica cement, an asphalt (or asphalt-like) binder and variouscombinations thereof. In some embodiments, the binder as a hydraulicbinder is or includes ASTM Type I Portland cement. In some embodiments,the binder, such as hydraulic binder, is introduced alone or with othercomponents, in dry form or as a slurry. The said other components may bepre-blended with the hydraulic binder, added upstream (prior to) ordownstream (after), either in wet or dry form. In some instances, thebinder, such as a hydraulic binder, is added dry for better mixing.Water is then re-introduced after blending to promote the hydraulicreaction. In other instances, the hydraulic binder is added in batches,intermixed with quantities of water, which may assist in reducing dustwhen blending. In addition, in some embodiments a combination of bindersis blended. Fillers and/or fibers may also be included. For example,filler and fibers that increase overall strength without compromisingother desired properties may be used with the at least one binder.Non-hydraulic binders may also be used, such as ones that require acatalyst to initiate curing. Additional binders may be those that form aputty or are used for mortar. A binder may be or may include one or morethermoplastic resins, and/or thermoset resins. The binder may be apetroleum based binder (e.g., asphalt).

Examples of the described invention are provided below. All exampleswere found to be compliant with environmental standards for stabilizedand/or remediated materials and may be deemed a recycled nonhazardousmaterial for re-use, using a 7-day leachate test, a metals analysis anda chemistry analysis.

In a first example, drill cuttings in an initial state were retrievedfrom a drill site and combined with a drying agent on day 1, thecombination was found to have a reduced moisture content (first state),which was less than the moisture content (initial moisture state) of thedrill cuttings. The drill cutting themselves had varying starting(initial) moisture levels; however, moisture content always decreasedafter addition of the drying agent. In these examples, afterincorporating the drying agent, the combination was friable, and weredried in an oven to achieve the second state. Thus, essentially, thecomposition transitioned from a liquid, slurry state to a dry,particulated state. Other suitable means for reducing the moisturecontent are acceptable, as has been previously described. Therepresentative drying agent used was cement kiln dust and wasincorporated at about 10% by weight of the total quantity of the drillcuttings.

After the above combination achieved the second state, a hydraulicbinder was added to the combination of drill cuttings and drying agent.The hydraulic binder was added in varying amounts, either as 4 wt. %(F-4), 8 wt. % (F-8) or 10 wt. % (F-10), in addition to water. Theseadditions were made on day 4. For one example, a hydraulic binder in anamount of 6 wt. % (F-6) followed by water was added on day 2, afterapproximately 72 hours. For all examples, the hydraulic binder was TypeI Portland cement and was added dry to form a homogeneous mixture withthe first combination. Water was added in these representative examplesto rewet and rehydrate and initiate the hydraulic reaction. Theformulations for each of F-4, F-6, F-8 and F-10 are provided in TABLE 1.

TABLE 1 combination hydraulic water (g) binder (g) (g) F-4 1332 53 50F-6 1294 78 52 F-8 1331 106 72 F-10 1346 135 77

F-4, F-6, F-8 and F-10 as stabilized materials were allowed to undergo ahydraulic reaction at room temperature. Before solidification, sampleswere extracted from each of the stabilized materials and formed intosmall round shaped articles. Each article was about 2¼ inches indiameter and about 3 inches thick. Two samples were extracted for F-8and F-10, hence the tables below show F-8-A and F-8-B (TABLE 4) andF-10-A and F-10-B (TABLE 5). At periodic time points, the samplearticles were evaluated to determine loss of moisture duringsolidification and curing, as depicted in TABLES 2, 3, 4, and 5,respectively. Each data represents an average of n=3. Wet density wasmeasured by weighing. Dry density was measured after adding thehydraulic binder and compacting in accordance with AASHTO), T-99.

TABLE 2 wet density dry density (lb/ft³) (lb/ft³) F-4 Day 1 130 — F-4Day 2 129 — F-4 Day 4 127 128 F-4 Day 7 — 127

TABLE 3 wet density dry density (lb/ft³) (lb/ft³) F-6 Day 2 130 — F-6Day 7 — 125

TABLE 4 wet density dry density (lb/ft³) (lb/ft³) F-8-A Day 3 — 116F-8-A Day 6 — 115 F-8-B Day 1 129 118 F-8-B Day 2 127 — F-8-B Day 3 126— F-8-B Day 6 125

TABLE 5 wet density dry density (lb/ft³) (lb/ft³) F-10-A Day 3 — 117F-10-A Day 6 — 117 F-10-B Day 1 130 118 F-10-B Day 2 127 — F-10-B Day 3126 — F-10-B Day 6 125

The data in TABLES 2-5-show that each stabilized material that underwenta hydraulic reaction by exhibited a loss of moisture, regardless of theamount of hydraulic binder that was incorporated therein. The drydensity provides an indication of the relative strength of each of thestabilized material at that time period because of a known correlationbetween dry density and strength, as previously described, and shown inTABLE 6. Thus, when only dry density values have been evaluated,compressive strength may be predicted.

Referring again to FIG. 5 , the drawing shows the compressive strengthsfor a hydraulic binder comprising Type I Portland cement, at thequantities shown in TABLE 6, i.e., 4 wt. % (C-4), 6 wt. % (C-6), or 8wt. % (C-8) of drill cuttings. Said compressive strengths were measuredfrom similar size and shaped articles as prepared for TABLES 2-5 (e.g.,a diameter of about 2¼ inches and a thickness of about 3 inches), wereallowed to solidify for 7 days prior to testing and evaluated formoisture and dry density (modified slightly from but in accordance withTexas Department of Transportation 113E) and compressive strength (inaccordance with ASTM D1633). The data in TABLE 6 represents an averageof n=2. Thus, a figure prepared with any specific hydraulic binder maybe used to predict the compressive strength of materials (secondcombinations provided as stabilized, solidified and/or recycledmaterials) as described herein when made with that specific hydraulicbinder. Accordingly, the dry densities of F-4, F-6, F-8-A, F-8-B, F-10-Aand F-10-10-B, which included the hydraulic binder comprising Type IPortland cement, may be used to predict the compressive strength, suchas shown in TABLE 6 and FIG. 5 . In view of TABLE 6, each of articlesF-4, F-6, F-8-A, F-8-B, F-10-A and F-10-10-B achieved a compressivestrength in excess of 200 psi.

TABLE 6 dry density compressive (lb/ft³) moisture strength (psi) C-4 11812.3 237 C-6 115 13.4 338 C-8 117 12.45 548

Additional samples from each of the stabilized examples F-4, F-6, F-8and F-10, were evaluated utilizing 7-day leachate tests, for petroleumhydrocarbons, in accordance with Laboratory Procedures for Analysis ofExploration & Production Waste, for parameters under LouisianaAdministrative Code 43:XIX, subpart 1, and analyzed in accordance withTexas Commission on Environmental Quality, TCEQ Method 1005. These dataare presented in TABLE 7, in which MDL is method detection limit, SQL issample detection level, and MQL is method quantification limit. Theresults in TABLE 7 were compared to known samples of 1-choloroctadecaneand 1-chlorooctane, each of which presented results having a greaterthan 97% accuracy level. The results of TABLE 7 demonstrate that none ofthe stabilized and/or recycled materials were found to leach detectableamounts of hydrocarbons.

TABLE 7 MDL SQL MQL Result (mg/dL) F-4  C6-C12 1.05 0.10 1.0 <0.10C12-C28 0.96 0.10 1.0 <0.10 C28-C35 1.13 0.11 1.0 <0.11 F-6  C6-C12 1.050.10 0.98 <0.10 C12-C28 0.96 0.09 0.98 <0.09 C28-C35 1.13 0.11 0.98<0.11 F-8  C6-C12 1.05 0.10 0.98 <0.10 C12-C28 0.96 0.09 0.98 <0.09C28-C35 1.13 0.11 0.98 <0.11 F-10  C6-C12 1.05 0.11 1.0 <0.11 C12-C280.96 0.10 1.0 <0.10 C28-C35 1.13 0.11 1.0 <0.11

Metals testing was performed on the stabilized materials of examplesF-4, F-6, F-8 and F-10, in which samples were retrieved after additionof the hydraulic binder and a period of solidification for 7 days. Thesetestings were in accordance with Environmental Protection Agency, EPAMethod 6010B and EPA Method 7471B. Data are presented in TABLE 8 andshow that the stabilized and recycled materials did not releasepotentially contaminating metals that are in excess of standards set bythe EPA.

TABLE 8 MDL SQL MQL Result (mg/kg) F-4 arsenic 0.162 0.004 0.022 1.10barium 0.206 0.005 0.022 2.03 cadmium 0.137 0.003 0.022 0.03 chromium0.245 0.005 0.022 0.67 lead 0.126 0.003 0.022 1.82 mercury 0.005 0.0050.034 — selenium 0.156 0.003 0.022 0.09 silver 0.211 0.005 0.022 0.01F-6 arsenic 0.162 0.004 0.022 1.01 barium 0.206 0.005 0.021 2.11 cadmium0.137 0.003 0.022 0.02 chromium 0.245 0.005 0.022 0.55 lead 0.126 0.0030.022 1.69 mercury 0.005 0.026 0.178 2.29 selenium 0.156 0.003 0.0220.08 silver 0.211 0.005 0.022 0.01 F-8 arsenic 0.162 0.004 0.022 0.97barium 0.206 0.005 0.021 1.95 cadmium 0.137 0.003 0.022 0.02 chromium0.245 0.005 0.022 0.68 lead 0.126 0.003 0.022 1.69 mercury 0.005 0.0260.172 3.34 selenium 0.156 0.003 0.022 0.09 silver 0.211 0.005 0.022 0.03F-10 arsenic 0.162 0.003 0.020 0.87 barium 0.206 0.004 0.020 2.89cadmium 0.137 0.003 0.020 0.02 chromium 0.245 0.005 0.020 0.61 lead0.126 0.003 0.020 1.47 mercury 0.005 0.025 0.164 2.17 selenium 0.1560.003 0.020 0.08 silver 0.211 0.004 0.020 0.01

Chloride testing was performed on the stabilized and recycled examplesF-4, F-6, F-8 and F-10, in which samples were retrieved after additionof the hydraulic binder and a period of solidification for 7 day. Thesetests were in accordance with Environmental Protection Agency, EPAMethod 300A. Data presented in TABLE 9 show that the stabilized andrecycled materials did not release potentially contaminating chloridethat exceed standards set by the EPA Environmental Protection Agency.

TABLE 9 MDL SQL MQL Result F-4 solids (%) 0.1 0.1 91.4 chloride (mg/dL)0.05 0.05 0.1 68.0 F-6 solids (%) 0.1 0.1 91.7 chloride (mg/dL) 0.050.05 0.1 89.0 F-8 solids (%) 0.1 0.1 91.7 chloride (mg/dL) 0.05 0.05 0.1110 F-10 solids (%) — — — chloride (mg/dL) 0.05 0.05 0.1 68.5

Together, the data shows that the stabilized and recycled materials weresafe and complied with federal and state standards for cementitious basematerials. As such, the materials described herein can be used safely asa road base material or as a filling material, such as for a well, drillhole or borehole.

In another example, drill cuttings were obtained from a drilling sitenear Premont, Tex. The drill cuttings were generally large, irregularlyshaped, sticky or muddy globs or large aggregated masses, as depicted inFIG. 2 . They had not been further manipulated. To these drill cuttings,only a drying agent was introduced by a blending unit, which was a pugmill. The representative drying agent used was cement kiln dust, and wasincorporated as 10% by weight of the total quantity of the drillcuttings. The output material after blending was air dried for sevendays, considered to be dried to a friable state. The output was small,particulated or granular, said particulated or granular output was dry,as depicted in FIG. 3 . Thereafter, Type I Portland cement was added inan amount that was between 6% and 8% by weight with addition of water,and small samples were compacted in accordance with AASHTO, T-99,generally to approximately 120 lb/cu-ft, as depicted in FIG. 8 . Sevendays after, a series of tests were performed, including 7-day leachatetests measuring hydrocarbons (TABLE 10, in accordance with LaboratoryProcedures for Analysis of Exploration & Production Waste for parametersunder Louisiana Administrative Code 43:XIX, subpart 1, and analyzed inaccordance with Texas Commission on Environmental Quality, TEC TCEQMethod 1005), metals testing (TABLE 11, in accordance with EnvironmentalProtection Agency, EPA Method 6010 or 7470 [for mercury] and EPA Method1312), chloride testing (TABLE 12, in accordance with EnvironmentalProtection Agency, EPA Method 300A), and pH testing (TABLE 12, inaccordance with Environmental Protection Agency, EPA Method 9045). Dataare provided in TABLES 10, 11 and 12.

TABLE 10 hydrocarbon MDL SQL MQL Result (mg/L)  C6-C12 0.5 0.5 5.01 <0.5C12-C28 0.5 0.5 5.01 <0.5 C28-C35 0.5 0.5 5.01 <0.5

TABLE 11 metal MDL SQL MQL Result (mg/L) arsenic 0.002 0.002 0.01 <0.002barium 0.007 0.007 0.01 0.128 cadmium 0.001 0.001 0.01 0.002 chromium0.003 0.003 0.01 0.0116 lead 0.004 0.004 0.01 <0.004 mercury 0.00020.0002 0.0005 <0.0002 selenium 0.002 0.002 0.01 <0.002 silver 0.0010.001 0.05 0.019

TABLE 12 MDL SQL MQL Result chloride 0.05 1.00 3.20 143.0 (mg/L) pH 8.89 (pH unit)

The remaining output material after blending (i.e., material forming thefirst combination) was laid on a surface of soil, the output materialwas generally laid to a depth of about six inches. One exemplary outputhad a surface of about 4700 square yards. This surface and depth ismerely representative. For example, the surface may be of any dimension.The depth may be any desired depth, ranging at least from about a fewinches to as many as several feet or more. Thereafter, the output wasallowed to rest for about 7 days (though more or less days, inaccordance with the description above, is acceptable). Only afterresting, was the output rehydrated by first adding to the surface, bothcement and water (e.g., added from tankers having suitable spreaders),followed by blending (e.g., with a tiller or rotor other suitableblending tool or machine) to combine the output with the cement andwater in order to form the second combination to initiate the hydraulicreaction. When fully blended, the blended material was allowed to curefor 7 days (the period of time depending, in part, on the type ofhydraulic binder). The top surface, after curing, may also be sealed orotherwise surface treated, coated and/or painted in any desired manner,as is understood in the art, such as to further minimize long-term wearand surface abrasion. Suitable surface treatments to the stabilized orrecycled materials described herein, such as when formed as a roadsurface include a bituminous surface treatment, chipseal, thin membranesurface, and sealing coats, to give examples.

A core sample from the above-described stabilized or recycled road basematerial was drilled and measured for hydrocarbons (in accordance withLaboratory Procedures for Analysis of Exploration & Production Waste forparameters under Louisiana Administrative Code 43:XIX, subpart 1, andanalyzed in accordance with Texas Commission on Environmental Quality,TCEQ Method 1005), for metals (in accordance with EnvironmentalProtection Agency, EPA Method 6010 or 7470 [for mercury] and EPA Method1312), for chloride (per Environmental Protection Agency, EPA Method300A), and pH (in accordance with Environmental Protection Agency, EPAMethod 9045). Data are provided in TABLES 13, 14 and 15.

TABLE 13 hydrocarbon MDL SQL MQL Result (mg/L)  C6-C12 0.5 0.05 0.5<0.05 C12-C28 0.5 0.05 0.5 <0.05 C28-C35 0.5 0.05 0.5 <0.05

TABLE 14 metal MDL SQL MQL Result (mg/L) arsenic 0.002 0.002 0.01 <0.002barium 0.007 0.007 0.01 0.197 cadmium 0.001 0.001 0.01 <0.001 chromium0.003 0.003 0.01 0.0178 lead 0.004 0.004 0.01 <0.004 mercury 0.00020.0002 0.0005 <0.0002 selenium 0.002 0.002 0.01 <0.002 silver 0.0010.001 0.05 <0.001

TABLE 15 MDL SQL MQL Result pH 9.78 (pH unit)

The TABLES 10, 11 and 12 illustrate output materials prior tosolidification. TABLES 13, 14 and 15 illustrate materials aftersolidification. Together, the data show that these stabilized materialswere safe and complied with federal and state standards for cementitiousbase materials suitable for use as a sub base or as a road material.

The stabilized or recycled materials described herein may be used safelyas a road base material and/or as a filling material, such as for awell, drill hole or borehole. As either a road base material or afilling material, the stabilized or recycled materials described hereinmay be applied to a soil surface, a subsurface or other type of surfacethat may include a cementitious component, an asphalt component or otherstructural component. For example, a stabilized or recycled materialdescribed herein may be one layer, or provided as a number of layers,for a road comprising one or a number of components, including a base, atreated base (permeable or otherwise), a hot mix, and a cement top.

In TABLE 16, stabilized materials processed as described herein wereobtained from seven drill wells in southern Texas at various locationsin the Eagle Ford Shale region, each of which were drilled on similardates (or within three months of each other). For TABLE 16, drillcuttings were processed in batches as the drill cuttings were removedfrom the well and after drilling mud was recaptured by a shaker system.In brief, drill cuttings from a single well were processed in batches,each batch included blending or comingling the drill cuttings taken offthe shaker system with about 10 wt. % drying agent (range: 8 wt. % to 12wt. %, using cement kiln dust) (forming the first combination) andstacking to rest on a surface or in a pit for at least three days or atleast seven days or more after blending to provide a stabilized materialin a second state; the average amount of days for resting varied withthe number of days it took finish the well and collect all the drillcuttings from the well. The batches were generally stacked together inone pit. One well took up to a few days to retrieve all the drillcuttings. On average, and preferably at a minimum, the stabilizedmaterial had rested for about seven days or more, after which a sample(in a dried or friable state, second state) was removed and tested inaccordance with the test methods identified in TABLE 16. All samplesprovided values below the standards, thereby considered stabilized andsuitable for re-use or for recycling.

TABLE 16 Result (mg/L) Test Method hydrocarbon  C6-C12 <0.09 TCEQ 1005C12-C28 <0.10 TCEQ 1005 C28-C35 <0.05 TCEQ 1005 benzene <0.004-0.185 1312/8021B metal arsenic <0.002-01    EPA 1312/6010 barium 0.347-1.433EPA 1312/6010 cadmium <0.001-0.005  EPA 1312/6010 chromium 0.0067-0.215 EPA 1312/6010 lead <0.004-0.01  EPA 1312/6010 mercury <0.0002-0.002(ppm) EPA 1312/6010 selenium 0.004-0.01  EPA 1312/6010 silver<0.001-0.01  EPA 1312/6010 zinc <0.01 SW 6010B chloride 245-364 (mg/L)EPA 300 pH 8.37-11.5 (pH unit) EPA 9045

Stabilized materials from six of the seven drill wells identified inTABLE 16 were further evaluated for compressive strength, in which arepresentative compressive strength value for a well sample is shown inTABLE 17. For TABLE 17, a sample was taken at any time after resting forabout seven days. Once taken, each sample was tested 7 days after it wassent, in accordance with Tex 120E, in which each sample when compactedfor testing had a generally uniform diameter of about 6 inches, an areaof about 28.3 inches and a height that ranged from about 7.69 to 8inches. Maximum loading of the samples was between 1275 and 3400 andpounds (lbs). The moisture content (moisture %) at time of molding wasalso measured, as provided in TABLE 17. These moisture content amountsrepresented a reduction in moisture of at least 20% based on the initialmoisture content of the drill cuttings (before addition of the dryingagent). The values in TABLE 17 confirm that the stabilized materials metthe requirements for and were suitable as a sub base road material,having a compressive strength at least greater than 35 psi.

TABLE 17 Height Dry density Strength Moisture (inch) (lb/ft³) (psi) (%)B-3 7.88 101.7 43 19.5 B-4 7.75 105.2 57 17.9 D-12 7.88 105.1 111 18.0D-13 8 103.1 114 18.0 D-14 7.94 101.6 50 18.5 D-15 7.69 104.1 44 19.2

In TABLE 18, further stabilized materials were evaluated by processingas described above for TABLE 16. These stabilized materials wereobtained by using drill cuttings from eleven different drill wells insouthern Texas at various locations in the Eagle Ford Shale region, eachof which were drilled on similar dates (or within three months of eachother). The values in TABLE 18 show the range of values that wereobtained from the eleven drill wells and confirm that these stabilizedmaterials when processed as described herein were safe, complying withfederal and state standards as stabilized materials suitable for use asa sub base or as a road material or as a recycled material. Compressivestrength data for these samples are provided in TABLE 19 for stabilizedmaterial obtained from ten of the drill sites, using testing asdescribed with TABLE 17. Maximum load of the samples in TABLE 19 was upto about 3000 lbs. (between about 1075 and about 2475 lbs). The moisturecontent measured at time of molding represented a reduction in moistureof at least 20% based on the initial moisture content of the drillcuttings (before addition of the drying agent). Data from TABLE 19 alsoconfirms that these stabilized materials met the requirements for andwere suitable as a sub base road material, having a compressive strengthof at least greater than 35 psi.

TABLE 18 Result (mg/L) Test Method hydrocarbon  C6-C12 <2 TCEQ 1005C12-C28 <2-14 TCEQ 1005 C28-C35 <2 TCEQ 1005 benzene <0.004 SW 8260Bmetal arsenic <0.01 SW 6010B barium 0.319-0.96  SW 6010B cadmium <0.005SW 6010B chromium 0.0054-0.016  SW 6010B lead <0.01 SW 6010B mercury<0.002 (ppm) EPA 245.1/7470 selenium <0.02 SW 6010B silver <0.01-0.02 SW 6010B zinc <0.01 SW 6010B chloride 97-503 (mg/L) EPA 300 pH 10.2-11.6(pH unit) EPA 4500

TABLE 19 Height Dry density Strength Moisture (inch) (lb/ft³) (psi) (%)AT-9 7.88 106.2 46 16.5 AT-10 7.89 105.4 66 15.3 G-1 8.38 99.4 84 20.4K-3 7.63 103.1 39 17.5 K-4 7.50 104.5 42 17.5 K-5 7.75 101.3 36 17.7 K-67.25 101.8 41 17.1 M-8 8.13 100.9 79 19.6 R-1 8.13 99.4 62 20.8 T-1 7.94104.2 36 15.9

In further examples, drill cuttings were processed as described withTABLE 16 from twenty-five additional drill well sites in southern Texasat various locations in the Eagle Ford Shale region, each of which weredrilled on similar dates (or within three months of each other). Thevalues in TABLE 20 show the range of values that were obtained for thestabilized materials processed independently from the 25 additionaldrill wells and confirm that these stabilized materials when processedas described herein were safe, complying with federal and statestandards as stabilized materials suitable for use as a sub base or as aroad material or as a recycled material. For TABLE 21, drill cuttingswere processed in a similar manner as described with TABLE 16, withcompressive strength data provided in TABLE 21. Samples in TABLE 21 weretested in accordance with AASHTO T-99 and ASTM standards (D698) for aProctor compaction test. The maximum load was up to about 1000 lb(amount ranged between about 510 and about 1030 lbs), in which eachsample had a diameter of about 4 inches, an area of about 12.5 inches,and a height that ranged from about 4.5 inches to about 4.7 inches.TABLE 21 also provides the moisture content (moisture %) measured at thetime of molding, which was a reduction in moisture of at least 20% basedon the initial moisture content of the drill cuttings (before additionof the drying agent). Data from TABLE 21 confirms that these stabilizedmaterials met the requirements for and were suitable as a sub base roadmaterial, having a compressive strength of 35 psi or greater.

TABLE 20 Result (mg/L) Test Method hydrocarbon  C6-C12  <2-2.5 TCEQ 1005C12-C28 <2-36 TCEQ 1005 C28-C35 <2 TCEQ 1005 metal arsenic <0.01 SW6010B barium 0.352-1.18  SW 6010B cadmium <0.005 SW 6010B chromium0.005-0.015 SW 6010B lead <0.01 SW 6010B mercury <0.002 (ppm) EPA245.1/7470 selenium <0.02 SW 6010B silver <0.01 SW 6010B zinc <0.01 SW6010B chloride 80-679 (mg/L) EPA 300 pH 10.7-11.9 (pH unit) EPA 4500

TABLE 21 Height Dry density Strength Moisture (inch) (lb/ft³) (psi) (%)AL-11 4.53 95.2 62 16.9 AL-12 4.59 104.6 41 11.1 AL-13 4.65 109.8 56 9.5BR-20 4.59 109.4 46 9.9 BR-21 4.68 114.1 55 9.5 BL-5 4.58 107.7 39 8.4BL-6 4.59 102.7 48 10.3 CS-17 4.60 110.1 72 11.0 CS-33 4.68 106.9 7910.1 GL-1 4.69 117.1 67 8.0 GL-2 4.72 115.6 45 8.2 J-11 4.55 123.3 686.5 J-12 4.67 109.7 63 9.8 J-13 4.55 120.9 65 6.7 KS-3 4.57 117.2 38 8.8ML-37 4.60 108.4 82 10.2 N-11-1 4.53 116.8 65 7.3 N-33-1 4.51 117.9 358.8 N-33-2 4.62 109.4 54 11.4 N-2-1 4.63 119.3 65 7.2 N-2-2 4.60 117.251 7.4 P-4 4.62 112.8 52 6.7 U-7 4.63 108.4 41 10.7 U-9 4.62 109.7 1008.9 W-1 4.53 118.0 38 9.0

In TABLE 22, stabilized materials were processed as described with TABLE16 and were obtained from a further eight drill wells in southern Texasat various locations in the Eagle Ford Shale region, each of which weredrilled on similar dates (or within two to three months of each other).The values in TABLE 22 show the range of values that were obtained fromthe eight drill wells and confirm that these stabilized materials whenprocessed as described herein were safe, complying with federal andstate standards as stabilized materials suitable for use as a sub baseor as a road material or as a recycled material. Compressive strengthtesting data of stabilized materials prepared from seven of the wellsites is provided in TABLE 23, in which samples were processed inaccordance with AASHTO T-99 and ASTM standards (D698) for a Proctorcompaction test, in which samples had a diameter of about 4 inches, anarea of about 12.5 inches, and a height that was about 4.6 to 4.7inches. Maximum load was up to 1000 lbs (between about 460 and about 950lbs). TABLE 23 also provides moisture content (moisture %) measured atthe time of molding, which was a reduction in moisture of at least 20%based on the initial moisture content of the drill cuttings (beforeaddition of the drying agent). Data from TABLE 23 confirms that thesestabilized materials met the requirements for and were suitable as a subbase road material, having a compressive strength of 35 psi or greater.

TABLE 22 Result (mg/L) Test Method hydrocarbon  C6-C12 <2 TCEQ 1005C12-C28  <2-2.4 TCEQ 1005 C28-C35 <2 TCEQ 1005 metal arsenic <0.01 SW6010B barium 0.414-0.988 SW 6010B cadmium <0.005 SW 6010B chromium0.005-0.014 SW 6010B lead <0.01 SW 6010B mercury <0.002 (ppm) EPA245.1/7470 selenium <0.02 SW 6010B silver <0.01 SW 6010B zinc <0.01 SW6010B chloride 74-526 (mg/L) EPA 300 pH 11.0-12.0 (pH unit) EPA 4500

TABLE 23 Height Dry density Strength Moisture (inch) (lb/ft³) (psi) (%)CS-64 4.65 115.6 62 5.7 N-34-2b 4.6 114.8 69 7.6 N-34-2 4.68 114.9 4810.1 N-37-1 4.65 112.6 35 8.6 N-42-4 4.63 116.3 60 7.6 N-53-1 4.58 118.472 7.1 P-5 4.65 116.9 39 7.8

Any of the stabilized materials from the examples may be used alone(once stabilized as described above) or in combination with binder(s)described herein and/or surface acting agent(s) described herein. Usedalone, the stabilized materials may be dumped, spread out on a surfaceor on the ground (either soil or other sub surface) to a desiredthickness and rolled to apply a density to the stabilized material. Aplurality of layers may be laid down, one above the other. In someembodiments, each layer (when more than one) may have a thickness thatis less than ten inches or less than eight inches. Each layer (when morethan one layer is applied) may generally be at least 2 inches, or 3inches, and often is at least 4 inches. There is no limit to the numberof layers comprised of the stabilized materials described herein thatmay be applied to a surface. Said one or more layers may be furthertreated, pigmented, or modified, e.g., for surface water repellence,etc.

In another example of further processing stabilized materials, thestabilized materials, once stabilized as described herein (caused toachieve the second state) are spread out to a desired thickness. Thespreading may be on a prepared road surface, dirt, or other type ofsurface to which a stabilized material may be laid out on. In oneexample, when laying out as a road material, the layer thickness afterspreading may be between about 4 inches and about 8 inches. The layerwhen spread is rolled. This may then be used a road base. This will havestrength of at least 35 psi. Alternatively, the rolled layer may bewetted and/or plowed, with or without cutting ruts therein. Whenwetting, a surface acting agent may be included. This may then beblended using an appropriate blending unit to blend the surface actingagent with at least a top surface of the layer, which may include a fewinches to half the depth or even to the full depth of the layer. Thislayer of stabilized material may also serve as a suitable surface fordriving on, including large trucks and/or construction equipment. Theprocess may be repeated in order to achieve a plurality of layers. Tosolidify (the one or plurality of layers), before the previouslydescribed blending or after said blending, a binder (e.g., acementitious binder, such as a cement or Type I Portland cement, withappropriate additives suitable for a road) may be applied thereon orspread out onto the wetted surface. With cement, a sufficient amount maybe included for a final concentration of cement to be between about 4wt. % and about 10 wt. %. In some embodiments, the final amount ofcement may be about 6 wt. %. Upon spreading the binder or cement, amixer is directed over the surface, mixing the surface as well as mixingto a desired depth below the surface. The depth may, in someembodiments, be up to about 6 inches, or may be more than six inches, orless than six inches. After mixing, water or an aqueous solution (onethat is suitable for use and for a next mixing with the binder, whenalready applied thereon) is sprayed on the surface of the mixture. Insome instances this water aqueous solution, rather than the priorwetting, may include the surface acting agent. The surface acting agentwhen included (in either wetting step) is typically included to a finalconcentration of up to about 1%, or may be up to about 0.5% or may be upto about 0.1%, or in any amount therein (generally not more than about0.5 wt. % or not more than about 1 wt. %). After addition of the wateror aqueous solution (with or without the surface action agent), there isfurther mixing, the mixing here is often either to the full depth of thelayer or near the full depth of the layer. Following mixing, the layermay optionally be compacted with a compactor and/or graded. In someembodiments, there may optionally be another mixing, in which mixing isgenerally not to the full depth, and may be only about or less thanabout half the depth of the layer. A further compaction may or may notoccur thereafter, at which time the road may already be ready for use ormay be allowed to set for several days (up to about 10 days) beforeallowing heavy traffic. Said preparation as described is a road materialsuitable for heaving construction equipment and heavy traffic thereon.Said preparation may include additional steps or fewer steps as desiredin order to achieve a solidified and stabilized material that may serveas a road material or as a base material for a road. Other uses are alsoacceptable with the stabilized materials described herein.

When the stabilized or recycled materials described herein include acementitious binder, the stabilized and solidified materials may be usedin addition to or as replacement to a cement treated base (permeable orother treated base). When the stabilized or recycled materials describedherein include an asphalt containing binder, such stabilized andsolidified materials may be used in addition to or as replacement to anasphalt treated base (permeable or other treated base). When thestabilized or recycled materials described herein include a bindersuitable for a lean concrete base or sub base, such stabilized andsolidified materials when finally formed may be used in addition to oras replacement to a lean concrete base or sub base. When the stabilizedor recycled materials described herein include a binder suitable for alime treated base or sub base, such stabilized and recycled materialswhen fully formed may be used in addition to or as replacement to a limetreated base or sub base.

Although representative processes and articles have been described indetail herein, those skilled in the art will recognize that varioussubstitutions and modifications may be made without departing from thescope and spirit of what is described and defined by the appendedclaims.

What is claimed is:
 1. A method of preparing a stabilized material thatis substantially friable, the method comprising: combining a dryingagent and a quantity of drill cuttings to form a first combination thatdoes not include a pozzolan that would cause the stabilized material tobe substantially non-friable, the quantity of drill cuttings having amoisture content between about 1% and about 45% by weight prior tocombining, the drying agent in the first combination being in an amountgreater than about 1% and less than a first upper weight percentage byweight of the drill cuttings, the drying agent causing the firstcombination to achieve a first state such that the liquid content of thefirst combination is less than the liquid content of the drill cuttingsprior to combining; causing the first combination to achieve a secondstate, the second state having liquid content that is at least the firstupper weight percentage by weight less than the liquid content of thedrill cuttings prior to combining; such that the causing the firstcombination to achieve the second state causes formation of thestabilized material that is substantially friable, wherein the dryingagent has an alkaline pH, wherein causing the first combination toachieve the second state includes waiting following the combining of thedrying agent and the quantity of drill cuttings to form the firstcombination that does not include the pozzolan that would cause thestabilized material to be substantially non-friable, and wherein thefirst combination in the second state is the stabilized material that issubstantially friable.
 2. The method of claim 1, wherein the dryingagent is a byproduct of a calcination reaction.
 3. The method of claim1, wherein the drying agent is in an amount between about 5% and toabout 12% by weight based on the total weight of the first combination.4. The method of claim 1, wherein the liquid content of the quantity ofdrill cuttings prior to combining is between about 5% and about 15% byweight.
 5. The method of claim 1, wherein the drying agent is in anamount from about 5% and about 10% by weight of the quantity of thedrill cuttings.
 6. The method of claim 1, wherein the waiting is for atleast seven days.
 7. The method of claim 1, wherein the drying agentincludes calcium carbonate.
 8. The method of claim 1, wherein the dryingagent includes less than 10% by weight crystalline silica.
 9. The methodof claim 1, wherein the drying agent is a non-pozzolan.
 10. The methodof claim 1, wherein the first upper weight percentage is 20% by weight.11. A method of preparing a stabilized material, the method comprising:combining ingredients consisting of a drying agent and a quantity ofdrill cuttings to form a first combination, the quantity of drillcuttings having a moisture content between about 1% and about 45% byweight prior to combining, the drying agent in the first combinationbeing in a first amount by weight of the drill cuttings, the dryingagent causing the first combination to achieve a first statesubstantially without pozzolanic reaction such that the moisture contentof the first combination is less than the moisture content of the drillcuttings prior to combining; causing the first combination to achieve afriable second state, the friable second state having moisture contentthat is a second amount by weight less than the moisture content of thedrill cuttings prior to combining, the second amount having a greaterabsolute magnitude than the first amount; such that the causing thefirst combination to achieve the second state causes formation of thestabilized material that is friable, wherein causing the firstcombination to achieve the second state includes waiting.
 12. The methodaccording to claim 11, wherein the waiting is for at least seven days.13. The method according to claim 11, wherein the first amount by weightof the drill cuttings comprises between about 1% and to about 20% byweight of the drill cuttings.
 14. The method according to claim 11,wherein the second amount is at least about 20% by weight.
 15. Themethod according to claim 11, wherein the drying agent has an alkalinepH, wherein the drying agent includes calcium carbonate, wherein thedrying agent includes less than 10% by weight crystalline silica. 16.The method according to claim 11, wherein the drying agent is anon-pozzolan.
 17. A method of preparing a friable stabilized material,the method comprising: combining a drying agent and a quantity of drillcuttings to form a first combination, the quantity of drill cuttingshaving a moisture content between about 1% and about 45% by weight priorto combining, the drying agent in the first combination being in anamount between about 1% and to about 20% by weight of the drillcuttings, the drying agent causing the first combination to achieve afirst state such that the moisture content of the first combination isless than the moisture content of the drill cuttings prior to combining;causing the first combination to achieve a friable second state, thefriable second state having moisture content that is at least about 20%by weight less than the moisture content of the drill cuttings prior tocombining; such that first combination that has achieved the friablesecond state is the stabilized material that is friable, wherein thedrying agent has an alkaline pH, wherein causing the first combinationto achieve the second state includes waiting; and causing the friablestabilized material to be spread out on a ground surface.
 18. The methodof claim 17, wherein the drying agent includes calcium carbonate andwherein the drying agent includes less than 10% by weight crystallinesilica.
 19. The method of claim 17, wherein the waiting is for at least36 hours.
 20. A method of preparing a stabilized material that issubstantially friable, the method comprising: combining (i) a dryingagent that does not include a pozzolan that would cause the stabilizedmaterial to be substantially non-friable and (ii) a quantity of drillcuttings that does not include the pozzolan that would cause thestabilized material to be substantially non-friable, to form a firstcombination that does not include the pozzolan that would cause thestabilized material to be substantially non-friable, the quantity ofdrill cuttings having a liquid content between about 1% and about 45% byat least one of weight and volume prior to combining, the drying agentin the first combination being in an amount greater than about 1% andless than a first upper percentage by at least one of weight and volumeof the drill cuttings, the drying agent causing the first combination toachieve a first state such that the liquid content of the firstcombination is less than the liquid content of the drill cuttings priorto combining; causing the first combination to achieve a second state,the second state having liquid content that is at least the first upperpercentage by at least one of weight and volume less than the liquidcontent of the drill cuttings prior to combining; such that the causingthe first combination to achieve the second state causes formation ofthe stabilized material that is substantially friable, wherein thedrying agent has an alkaline pH, wherein the drying agent includescalcium carbonate, wherein the drying agent includes less than 10% byweight crystalline silica, wherein causing the first combination toachieve the second state includes waiting following the combining of (i)the drying agent that does not include the pozzolan that would cause thestabilized material to be substantially non-friable and (ii) thequantity of drill cuttings that does not include the pozzolan that wouldcause the stabilized material to be substantially non-friable to formthe first combination that does not include the pozzolan that wouldcause the stabilized material to be substantially non-friable, andwherein the first combination in the second state is the stabilizedmaterial that is substantially friable.